Packaging for surgical sutures

ABSTRACT

A surgical suture package for storing at least one surgical suture includes an outer jacket having a plurality of panels foldably connected to each other and adapted to fold upon each other to form an inner pocket and an inner retainer for positioning within the pocket of the outer jacket. The inner retainer includes a row of support panels having a main support panel for supporting the at least one suture, and a pair of side support panels foldably connected to the main support panel along respective opposed major sides of the main support panel. The side support panels are adapted to be folded onto the main support panel to at least partially enclose the at least one suture. A cover panel is foldably connected to the main support panel along a minor side of the main support panel, and is adapted to be folded onto the support panels. A row of closure panels including a main closure panel is foldably connected to the main support panel along a second minor side of the main closure panel, and a pair of side closure panels is foldably connected to the main closure panel along respective opposed major sides of the main closure panel. The main closure panel is adapted to be folded along the second minor side of the main support panel onto the main support panel and the side closure panels are adapted to be folded along the major sides of the main closure panel to at least partially enclose the support and cover panels.

TECHNICAL FIELD

The present disclosure relates generally to surgical suture packaging,and, more particularly, relates to a foldable suture package forretaining at least one suture.

BACKGROUND

Surgical packages for sutures with attached needles are widely known inthe art. Two commonly used suture packages include a molded plasticretainer and a folded paper retainer. A conventional molded plasticretainer incorporates a molded channel, e.g., a racetrack channel, forreceiving a plurality of sutures and a needle park for mounting theneedles attached to the sutures. The folded paper retainer is generallyconstructed from paperboard, fiberboard or other suitable material, andincorporates a plurality of panels which are folded to form an envelopein which the wound suture(s) is placed.

While molded plastic retainers can receive a number of sutures withattached needles of various sizes, the folded paper retainers aregenerally more cost effective and less wasteful than the plasticretainers. However, drawbacks of conventional folded paper retainersinclude difficulties in opening the retainer, and in accessing andremoving the stored sutures. In addition, if several sutures are storedin a folded paper retainer, these sutures have a tendency to tangle ifprovisions are not made to maintain the sutures separated.

SUMMARY

Accordingly, the present disclosure relates to improvements in surgicalsuture packaging. In one preferred embodiment, a surgical suture packagefor storing at least one surgical suture includes an outer jacket havinga plurality of panels foldably connected to each other and adapted tofold upon each other to form an inner pocket and an inner retainer forpositioning within the pocket of the outer jacket. The inner retainerincludes a row of support panels having a main support panel forsupporting the at least one suture, and a pair of side support panelsfoldably connected to the main support panel along respective opposedmajor sides of the main support panel. The side support panels areadapted to be folded onto the main support panel to at least partiallyenclose the at least one suture. A cover panel is foldably connected tothe main support panel along a minor side of the main support panel, andis adapted to be folded onto the support panels. A row of closure panelsincluding a main closure panel is foldably connected to the main supportpanel along a second minor side of the main closure panel, and a pair ofside closure panels is foldably connected to the main closure panelalong respective opposed major sides of the main closure panel. The mainclosure panel is adapted to be folded along the second minor side of themain support panel onto the main support panel and the side closurepanels are adapted to be folded along the major sides of the mainclosure panel to at least partially enclose the support and coverpanels.

Means for retaining the side closure panels in a folded condition atleast partially enclosing the support and cover panels may be provided.Alternatively, the side closure panels include a tab and slotarrangement for releasably retaining the side closure panels in a foldedcondition at least partially enclosing the support and cover panels.

The outer jacket includes at least two outer panels foldably connectedto each other to define the pocket. Preferably, the outer jacketincludes a row of three outer panels foldably connected to each other todefine the pocket. The outer panels include a central outer panel andside outer panels foldably connected to respective major sides of thecentral outer panel. The side outer panels include a tab and slotarrangement for retaining the outer panels in a folded condition. Theside outer panels may be each connected to the central outer panelthrough a gusset. The outer jacket further may include a top panelconnected to a minor side of one of the side outer panels. The top panelis adapted to fold along an intermediate fold line thereof tosubstantially enclose the pocket formed by the outer enclosure. The toppanel may include a locking slit dimensioned to receive a minor side ofthe other of the side panel or central outer panel.

The cover panel of the inner retainer may include a suture receivingslot for receiving and supporting a suture end portion of the at leastone suture. Alternatively, a suture clip is attachable to the at leastone suture. A plurality of sutures may be supported within the innerretainer whereby the suture clip is connected to each end portion of thesutures.

The suture package may include an outer envelope which defines a pouchfor receiving the inner retainer member and the outer jacket in thefolded conditions thereof.

In another preferred embodiment, a suture package for a plurality ofsurgical needled sutures includes first and second rows of panels. Thefirst row includes a main support panel for supporting a plurality ofneedled sutures, and a pair of side support panels foldably connected tothe main support panel along respective opposed major sides of the mainsupport panel, whereby the side support panels are adapted to be foldedonto the main support panel to at least partially enclose the sutures.The second row includes a cover panel foldably connected to the mainsupport panel along a first minor side of the main support panel andadapted to be folded onto the support panels. A suture clip isattachable to each of the suture end portions, preferably, proximal ofthe needles to permit concurrent removal of the sutures from the supportpanels.

The suture package may include a third row having a plurality of closurepanels. The closure panels include a main closure panel foldablyconnected to the main support panel along a second minor side of themain closure panel, and a pair of side closure panels foldably connectedto the main closure panel along respective opposed major sides of themain closure panel. The main closure panel is adapted to be folded alongthe second minor side of the main support panel onto the cover panel andthe side closure panels are adapted to be folded along the major sidesof the main closure panel to at least partially enclose the support andcover panels.

An outer jacket may be provided. The outer jacket has at least two outerpanels foldably connected to each other and adapted to fold upon eachother to form an inner pocket. The inner pocket is adapted to at leastpartially accommodate the support, cover and closure panels in a foldedcondition thereof. The outer jacket preferably includes three panels.

A method of packaging a plurality of sutures is also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present disclosure will be betterappreciated by reference to the drawings wherein:

FIG. 1 is a front plan view of a suture package including an envelope, afoldable outer jacket and a foldable inner retainer constructed inaccordance with the principles of the present disclosure;

FIG. 2 is a front plan view of the outer jacket with the inner retainerpositioned within the pocket of the outer jacket;

FIG. 3 is a front plan view of the outer jacket in an unfoldedcondition;

FIGS. 4-6 are plan views illustrating the preferred sequence of foldingthe outer jacket to form the pocket;

FIG. 7 is a front plan view of the inner retainer in an unfoldedcondition; and

FIGS. 8-12 are plan views illustrating the preferred sequence of loadingand folding the inner retainer to form a suture compartment for aplurality of sutures.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings wherein like reference numerals illustratesimilar components throughout the several views, FIGS. 1-2 illustratethe suture package in accordance with the present disclosure depictedgenerally as reference numeral 10. Suture package 10 includes envelope50, outer jacket 100 and inner retainer 200 which is secured within theouter jacket 100. Envelope 50 receives outer jacket 100 and innerretainer 200 when the outer jacket 100 and the inner retainer 200 are intheir respective folded conditions. In FIG. 2, envelope 50 is removed.

Envelope 50 includes top sheet 52 and bottom sheet 54. Top sheet 52 maybe formed of a clear plastic, such as a polyethylene, or other likematerial. Bottom sheet 54 may be constructed from paperboard,fiberboard, Tyvek®, aluminum foil or other like material. The materialsof construction of top and bottom sheets 52, 54 preferably prevent orgreatly impede the transmission of moisture therethrough. Top sheet 52and bottom sheet 54 are generally rectangular in shape and substantiallythe same size. Sheets 52, 54 are adhered together along their respectiveperipheries by an adhesive, cement, etc. or the like. In one preferredembodiment, a peripheral line of peelable adhesive is used. Sheets 52,54 define flaps 56, 58 at one corner, which are devoid of adhesive.Flaps 56, 58 remain unattached to be readily grasped by the operator tofacilitate at least partial separation of sheets 52, 54 when openingenvelope 50. Envelope 50 hermetically seals outer jacket 100 and innerretainer 200, preventing contaminates from reaching the stored sutures300 and, as mentioned above, minimizing passage of moisture. Outerjacket 100 is visible through top sheet 52 of envelope 50 as depicted inFIG. 1.

With reference to FIGS. 2-3, outer jacket 100 will be discussed. Outerjacket 100 defines inner pocket 102 when in the folded condition toreceive folded inner retainer 200. In FIG. 3, outer jacket 100 is shownin a flat, unfolded or pre-folded state. Outer jacket 100 may beconstructed from paperboard, fiberboard, cardboard or any other fibrousmaterial such as Tyvek®, or like material. Outer jacket 100 ispreferably die cut to form a series of interconnected panels.Specifically, outer jacket 100 includes panels 110, 120, 130 and toppanel 140. Panels 110, 120, 130 are generally rectangular in shape andsubstantially the same size. Panels 110, 120, 130 each have respectiveopposed major sides 112, 122, 132 also referred to as longitudinal edgeswith reference to reference longitudinal axis “x”, and respectiveopposed minor sides 114, 124, 134, also referred to as transverse edges.Centrally positioned panel 110 includes a foam strip 150 adjacent itslower minor side 114. Foam strip 150 functions as a stop when innerretainer 200 is inserted within pocket 102 of folded outer jacket 100.Foam strip 150 may also maintain the folded panels 120, 130 a desired orpredetermined distance from centrally positioned panel 110. Panel 130includes longitudinal slot 136 along one major side 132 adjacentcentrally positioned panel 110. Panel 120 includes tab 126 formedtherein. Tab 126 is dimensioned to cooperate with longitudinal slot 136to releasably secure panels 110, 130 thereby securing the panels 110,120, 130 a folded condition.

Gussets 160, 170 respectively interconnect panels 120, 130 and centrallypositioned panel 110. Gussets 160, 170 are substantially triangular inshape tapering inwardly toward the lower end of outer jacket 110.Gussets 160, 170 prevent panels 120, 130 from collapsing onto, andcontacting panel 110 when the panels 120, 130 are folded onto the panel110. Gussets 160, 170 also provide depth to the folded outer jacket 100thereby increasing the size of pocket 102 formed by folded panels 110,120, 130. Gussets 160, 170 define double fold lines corresponding tomajor sides 112, 122, 132 about which panels 120, 130 fold ontocentrally positioned panel 110. The triangular or tapering configurationof gussets 160, 170 ensures that pocket 102 has a greater depth adjacentthe upper or open end of outer jacket 100 and a lesser depth toward thelower end of outer jacket 100. This arrangement permits folded innerretainer 200 to be readily inserted into pocket 102 while ensuring thatthe inner retainer 200 is frictionally engaged within the pocket 102adjacent the lower end of the outer jacket 100.

With continued reference to FIGS. 2-3, top panel 140 is foldablyconnected to panel 120 along upper minor side 124 of the panel 120. Inthis regard, top panel 140 may be folded backwards to expose thecontents within outer jacket 100. Top panel 140 includes intermediatefold line 142 which thereby defines upper top panel portion 144 andlower top panel portion 146. Top panel portion 144 is adapted to foldalong fold line 142 onto top panel portion 146 to enclose the pocket 102defined by outer jacket 100. Top panel portion 144 includes arcuate slit148 which is configured and dimensioned to receive upper minor side 114of panel 110 or upper minor side 134 of panel 130 to secure top panel140 in a folded condition.

The process of folding outer jacket 100 to form pocket 102 for receivinginner retainer 200 will be described in detail. Initially, withreference to FIG. 3, panel 130 is folded along major side 132 onto panel110 such that the rear surface 130 a of the panel 130 is exposed asdepicted in FIG. 4. Thereafter, panel 120 is folded along major side 122onto panels 110, 130 such that rear surface 120 a of the panel 120 isexposed as shown in FIG. 5. (Alternatively, panels 110, 130 may befolded onto panel 120.) With panels 110, 120, 130 folded onto eachother, tab 126 of panel 120 is then inserted into slot 136 of panel 130to releasably secure the panels 120, 130. FIG. 6 illustrates the frontside of outer jacket 100 with top panel 140 in an open position andpocket 102 accessible for reception of the folded inner retainer 200.

Referring now to FIG. 7, inner retainer 200 will be discussed. Innerretainer 200 is shown in a flat, unfolded or pre-folded state. Innerretainer 200 is constructed from paper or any other like materialidentified hereinabove in connection with outer jacket 100. Innerretainer 200 includes a first or central row of support panels, namely,centrally positioned main support panel 210, and side support panels212, 214 on each side of the main support panel 210. Main support panel210 defines openings 216 adjacent upper and lower minor sides 218 of themain support panel 210. Openings 216 are sized and configured to receivewinding pins or pegs of a winding device (not shown). Sutures 300 may bewound about the winding pins either manually or through automated means.Main support panel 210 is generally rectangular in configurationdefining major sides 220 and minor sides 218. Side support panels 212,214 are generally trapezoidal in shaped and have major sides 222 whichare interconnected to major sides 220 of main support panel 210 throughgusset 224. Gussets 224 define double fold lines corresponding to majorsides 220, 222 about which side support panels 212, 214 fold onto mainsupport panel 210. Gussets 224 increase the depth of the folded supportpanels to thereby provided sufficient space to store sutures 300.

Inner retainer 200 further includes cover panel 230 which forms a secondrow of panels of the inner retainer 200. Cover panel 230 includes minorside 232 which is connected to upper minor side 218 of main supportpanel 210 through gusset 234. Gusset 234 defines a double fold lineabout which panel 230 folds onto main support panel 210. Cover panel 230may have suture receiving slot 236 extending from a peripheral edge(e.g., major side 238) of the cover panel 230 into the central area ofthe cover panel 230. Suture receiving slot 234 may be utilized toreceive end portions of sutures 300 to assist supporting the suture endportions and attached needles 400 within inner retainer 200 as will bediscussed. Alternatively, suture receiving slot 236 may receive sutureclip 500 which is attached to the end portions of sutures 300. As afurther alternative, cover panel 230 may be devoid of suture receivingslot 236.

Inner retainer 200 further includes a third row of closure panels,namely, central closure panel 240 and a pair of side closure panels 242,244 connected to the central closure panel 240. Central closure panel240 is connected along minor side 246 to minor side 218 of main supportpanel 210 through gusset 248. Gusset 248 defines a double fold lineabout which central panel 242 folds onto main support panel 210. Centralclosure panel 242 defines an arcuate or recessed lower minor side 250.The recessed configuration of minor side 250 assists in exposing thestored needles 400 of the assembled package as will be discussed.Central closure panel 242 further defines major sides 252. Side closurepanels 242, 244 include major sides 254, 256, and are connected tocentral closure panel 242 through gussets 258, 260 respectively. Gussets258, 260 each define double fold lines. Side closure panels 242, 244include tabs 262 and slots 264 respectively. Slots 264 of side panel 244are sized to receive tabs 262 of side panel 242 to facilitate retainingthe side closure panels 242, 244 in a folded condition.

The preferred sequence of loading inner retainer 200 with sutures 300and folding the inner retainer 200 will be discussed. Initially,pre-folded inner retainer 200 is placed on a winding device such thatopenings 216 are aligned with and receive winding pegs of the windingdevice (not shown). Individual sutures 300 with attached needles 400 arewound around the winding pegs either manually or through an automatedsuture winding process. Sutures 300 may be wrapped around the windingpegs collectively as a bundle, or individually. Preferably, sutures 300have suture clip 500 attached to the suture end portions 302 adjacentneedles 400. Suture clip 500 retains the sutures in a bundle andpreferably in spaced relation to minimize tangling of the suture ends302. Suture clip 500 also permits sutures 300 to be removed from innerretainer 200 as a bundle rather than as individual sutures. Suture clip500 may be attached to the individual sutures 300 prior to or subsequentto the winding process. In one preferred embodiment depicted in FIG. 7A,suture clip 500 includes resilient finger 502. Resilient finger 502 maybe displaced or pivoted away from suture clip 500 as shown bydirectional arrow “p” to receive sutures 300. Preferably, finger 502 hassufficient resiliency to return to its normal position to frictionallyengage sutures 300. Other arrangements for suture clip 500 are alsoenvisioned including separately mounted clamps, an aperture, a slitextending through the suture clip 500, etc. Once sutures 300 have beenwound onto the winding pegs, the winding pegs may be removed and innerretainer 200 may be folded.

Once sutures 300 are in position supported by central support panel 210as shown in FIG. 7, side support panel 212 is folded along the doublefold line sides defined by gusset 220 onto the central support panel210. Side support panel 214 is then along the double fold line definedby gusset 224 onto the rear side 212 a of side support panel 212 toexpose the rear side 214 a of the side support panel 214. FIG. 8illustrates side support panels 212, 214 in their folded conditions oncentral support panel 210. As appreciated, gussets 224 providesufficient depth to the folded support panels 210, 212, 214 toaccommodate the loaded sutures 300.

With reference to FIG. 9, cover panel 230 is folded onto main supportpanel 210 to cover the wound sutures 300 with the exception of thesuture end portions 302 adjacent the attached needles 400 and sutureclip 500. Suture clip 500 and attached needles 400 are preferablypositioned on the rear side 230 a of cover panel 230 and preferably hungin suspension over minor side 218 of main support panel 210. In thealternative, clip 500 may be manipulated to engage suture receiving slot236 of cover panel 230. As a further alternative, individual sutureportions 304 on the side of suture clip 500 away from needles 400 arepassed through suture receiving slot 236 of cover panel 230 and coverpanel 230 is folded onto main support panel 210 as depicted in FIG. 9A.In this manner, suture receiving slot 236 supports the individualsutures 300 with attached needles 400 and suture clip 500 in suspendedmanner against rear side 230 a of cover panel 230.

Once cover panel 230 is in position, central closure panel 240 is foldedin the direction of the arrow “a” of FIG. 9 along the double fold lineprovided by gusset 248 onto the rear side 230 a of cover panel 230. FIG.10 illustrates central closure panel 240 in the folded condition. InFIG. 10, the rear side 210 a of needle support panel 210 is shown. Sideclosure panels 242, 244 are then folded around main support panel side210 and tabs 262 are inserted within slots 264 to secure the sideclosure panels 242, 244 together as depicted in FIG. 11. Preferably,suture clip 500 is manipulated to hang over the arcuate minor side 250to provide enhanced access to the suture clip 250, and attached needles400 and sutures 300 as depicted in FIG. 12.

Referring again to FIG. 2, inner retainer 200 is then positioned withinpocket 102 of outer jacket 100 and advanced to a position where theouter jacket 100 frictionally engages the inner retainer 200 and/or theinner retainer 200 abuts foam strip 150. Top panel portion 144 is foldedalong fold line 142 onto top panel portion 146. In the folded position,tab 148 of panel portion 144 engages the top minor side 114 of panel110, thus securing inner retainer 200 within outer jacket 100. Finally,inner retainer 200, securely contained within outer jacket 100, issealed within outer envelope 50.

In order to access suture bundle 300, outer envelope 50 is opened byseparating flaps 54, 56. Next, tab 148 of cover panel 140 is disengagedfrom the top minor side 114 of panel 110 and panel 140 is folded backalong fold line 124. Inner retainer 200 is then removed from pocket 102of outer jacket 100. Panels 242, 244 are then unfolded first bydisengaging tabs 262 of panel 242 from slots 264 of panel 244. Suturebundle 300 is thus accessible and may be removed as a bundle usingsuture clip 500. Removal of the sutures 300 as a bundle greatlyminimizes the potential of suture tangling which would otherwise existif the sutures were removed individually. If desired, the remainder ofinner retainer 200 may be unfolded prior to removing the sutures 300.

It will be understood that various modifications may be made to theembodiments disclosed herein. Therefore, the above description shouldnot be construed as limiting, but merely as exemplifications ofpreferred embodiments. Those skilled in the art will envision othermodifications within the scope and spirit of the claims append hereto.

1. A surgical suture package for storing at least one surgical suture,which comprises: an outer jacket including a plurality of panelsfoldably connected to each other and adapted to fold upon each other toform an inner pocket; and an inner retainer for positioning within thepocket of the outer jacket, the inner retainer including: a row ofsupport panels, the support panels including a main support panel forsupporting the at least one suture, and a pair of side support panelsfoldably connected to the main support panel along respective opposedmajor sides of the main support panel, whereby the side support panelsare adapted to be folded onto the main support panel to at leastpartially enclose the at least one suture; a cover panel foldablyconnected to the main support panel along a minor side of the mainsupport panel, the cover panel being adapted to be folded onto thesupport panels; and a row of closure panels, the closure panelsincluding a main closure panel foldably connected to the main supportpanel along a second minor side of the main closure panel, and a pair ofside closure panels foldably connected to the main closure panel alongrespective opposed major sides of the main closure panel, whereby themain closure panel is adapted to be folded along the second minor sideof the main support panel onto the main support panel and the sideclosure panels are adapted to be folded along the major sides of themain closure panel to substantially enclose the support and coverpanels.
 2. The suture package according to claim 1 including means forretaining the side closure panels in a folded condition at leastpartially enclosing the support and cover panels.
 3. The suture packageaccording to claim 1 wherein the side closure panels include a tab andslot arrangement for releasably retaining the side closure panels in afolded condition at least partially enclosing the support and coverpanels.
 4. The suture package according to claim 1 wherein the outerjacket includes at least two outer panels foldably connected to eachother to define the pocket.
 5. The suture package according to claim 4wherein the outer jacket includes a row of three outer panels foldablyconnected to each other to define the pocket, the outer panels includinga central outer panel and side outer panels foldably connected torespective major sides of the central outer panel.
 6. The suture packageaccording to claim 5 wherein the side outer panels include a tab andslot arrangement for retaining the outer panels in a folded condition.7. The suture package according to claim 6 wherein the side outer panelsare each connected to the central outer panel through a gusset.
 8. Thesuture package according to claim 7 wherein the outer jacket includes atop panel connected to a minor side of one of the side outer panels, thetop panel adapted to fold along an intermediate fold line thereof tosubstantially enclose the pocket formed by the outer enclosure.
 9. Thesuture package according to claim 8 wherein the top panel includes alocking slit dimensioned to receive a minor side of the other of theside panel or central outer panel.
 10. The suture package according toclaim 8 wherein the cover panel includes a suture receiving slot forreceiving and supporting a suture end portion of the at least onesuture.
 11. The suture package according to claim 1 including a sutureclip attachable to the at least one suture.
 12. The suture packageaccording to claim 11 including a plurality of sutures supported withinthe inner retainer, the suture clip being connected to each end portionof the sutures.
 13. The suture package according to claim 1 including anouter envelope, the outer envelope defining a pouch for receiving theinner retainer member and the outer jacket in the folded conditionsthereof.
 14. The suture package according to claim 1, further includinga removable suture clip attachable to each of the suture end portions topermit concurrent removal of the sutures from the support panels.